Ancillary Objects for Thermal Gradient Control in Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing techniques face issues with thermal gradients during the cooling process, leading to geometrical inaccuracies and mechanical property disruptions in generated objects due to variability in temperature, resulting in issues like curling and warping.
Innovation Solution
The generation of an ancillary object with a thermal profile similar to the underlying fabrication chamber, which acts as a sacrificial 'thermal blanket' to reduce vertical thermal gradients, allowing for fewer layers of untreated build material to manage thermal gradients effectively, thereby reducing the number of layers needed and the time required for object generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple layers of untreated build material are used to manage thermal gradients, then thermal gradient control is improved, but the number of layers and object generation time increase
Solution Approach 1:
The patent introduces sacrificial ancillary objects that are deliberately designed to be temporary and disposable. These objects serve their thermal management function during the build process and are then removed, replacing the need for multiple layers of untreated build material that would otherwise need to be deposited and later removed anyway.
Solution Approach 2:
The ancillary objects act as intermediary thermal management elements between the built object and the build chamber environment. They provide controlled thermal profiles during the build process and are specifically designed to manage heat distribution without becoming part of the final product, thus reducing the need for extensive untreated build material layers.
2Manufacturing precision
If ancillary objects are generated to reduce thermal gradients, then warping and curling are reduced, but the number of objects to be generated increases
Solution Approach 1:
The patent combines the thermal management function with the build process itself by generating ancillary objects using the same additive manufacturing system and process that creates the primary objects. This integration allows thermal control to be achieved without requiring separate external equipment or processes, and the ancillary objects can be generated in the same build chamber alongside the primary objects.
Solution Approach 2:
The ancillary objects are designed as temporary, sacrificial elements that serve their thermal management purpose and are then removed. They are intentionally made disposable to avoid complicating the final product assembly, and their temporary nature allows them to be optimized purely for thermal control function rather than structural requirements.
3Temperature
If heat lamps are used to control cooling rates, then thermal gradient control is improved, but device complexity and energy consumption increase
Solution Approach 1:
The ancillary objects provide self-service thermal management by virtue of their presence and thermal properties during the build process. They naturally regulate heat distribution through their material properties and geometry, eliminating the need for external active heating devices like heat lamps. The thermal control is inherent to the build process itself rather than requiring separate control systems.
Solution Approach 2:
The ancillary objects serve as intermediary thermal elements that mediate heat transfer between the built object and the build chamber environment. They provide passive thermal control through their physical presence and material properties, replacing the need for active thermal management equipment and simplifying the overall system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes thermal gradients, reduces the risk of warping and curling, and optimizes the use of build material and space within the fabrication chamber, while potentially eliminating the need for heat lamps to control cooling rates.
Implementation Method 1
acts as a sacrificial 'thermal blanket' to reduce vertical thermal gradients
Data Source
AI summary
In an example, a method includes in an additive manufacturing process, generating a first object and generating an ancillary object on top of the first object to reduce a thermal gradient of the first object during cooling.